Prosthetic Appliance Transfer Kit and Method

ABSTRACT

A kit and method is disclosed to facilitate the transferring of a prosthetic appliance to the skin of a wearer. The kit includes first and second transfer portions, which may be provided in combined form. The first transfer portion includes a prosthetic appliance and a release film. The second transfer portion includes a transfer substrate, an adhesive layer and a release coat therebetween. The second transfer portion may include a seal layer disposed between the adhesive layer and the release coat. The kit may include a package portion which may non-adhesively restrain the other components so as to protect and display the prosthetic while enabling the package portion to be opened without causing damage to the remainder of the kit. A method for producing the kit is disclosed and involves the use of a cavity mold and respective retainer plate to produce the requisite transfer portions.

RELATED APPLICATIONS

Not applicable.

TECHNICAL FIELD

The present invention relates generally to three-dimensional prostheticdevices for use as components in makeup and visual special effects. Moreparticularly, the invention relates to a kit and method for facilitatingthe rapid transfer of prosthetic appliances to the skin of a wearer.

BACKGROUND

Prosthetic appliances are commonly used by special effects professionalsin the world of stage and screen makeup to simulate highly realisticlooking deformities, injuries, unnatural features and modifications tothe general structural appearance of a subject's face or body. There isa preference among many professional makeup artists to transfer certainprosthetic appliances to a subject without the need for the artist tomake direct contact with the appliance at any point from its creation toits application. This is particularly important when dealing withappliances made substantially of tacky substances, such as, for example,water-based pressure-sensitive adhesives.

The Applicant previously developed prosthetic transfer solutions whichremain some of the most widely-used by professional makeup artiststoday. In a typical such process, a prosthetic is created with anassociated release film several days or weeks in advance of itsapplication. When the time comes to apply the prosthetic to a subject,the artist applies adhesive to the front of the appliance using a spongeor brush, places a separate piece of water-slide transfer paper orwater-slide fabric to the front of the appliance with the water slidecoat in contact with the adhesive, the release film is removed from theback side of the appliance, the appliance is placed on the skin of thesubject, the transfer paper is removed with the application of water,and the artist must manually apply a powder and/or liquid sealer toeliminate the tackiness of the prosthetic and to protect it. However,the multiple steps, materials and chemicals required in the prior knownprocesses make creating and transferring professional-qualityprosthetics too expensive, impractical, and complicated for the averageconsumer.

What is needed is a convenient, compact, inexpensive and easy-to-use kitfor applying a prosthetic appliance to the skin of a wearer whileachieving professional-quality results. Moreover, such a kit shouldenable the average consumer to achieve these professional results whileeliminating one or more steps conventionally required of professionalmakeup artists. Also needed are methods for efficiently making and usingsuch kits, while minimizing cost and complexity and optimizing theresults.

SUMMARY

Certain deficiencies of the prior art may be overcome by the provisionof a kit for transferring a prosthetic appliance to the skin of awearer, and a method for using and producing such a kit. The kit maycomprise a first and second transfer portion in either combined orindependent form. The first transfer portion may include a prostheticappliance and a release film. The prosthetic appliance may have an outersurface and an inner surface. The release film may have a first side anda second side, with the first side being peelably releasably bonded tothe inner surface. The second transfer portion may include a transfersubstrate, an adhesive layer and a water soluble release coat disposedtherebetween. In certain embodiments, the second transfer portion mayinclude a sealant layer disposed between the adhesive layer and therelease coat. The first transfer portion and second transfer portion maybe separably joined by way of the second side being peelably releasablybonded to the adhesive layer. Embodiments of the kit may include amultiplicity of prosthetic appliances and a package portion. Optimalmethods of producing and using such a kit are also described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

Further advantages of the present invention may become apparent to thoseskilled in the art with the benefit of the following detaileddescription of the preferred embodiments and upon reference to theaccompanying drawings in which:

FIG. 1 is a diagrammatic partial cross-sectional view of one example ofa kit in accordance with the present invention, in which the secondtransfer portion includes a seal layer and the first and second transferportions are separably joined;

FIG. 2 is a diagrammatic partial cross-sectional view of an alternativeembodiment of a kit, in which the second transfer portion includes aseal layer, the first and second transfer portions are provided inindependent form, and the second transfer portion includes a secondrelease film peelably releasably bonded to the adhesive layer;

FIG. 3 is a diagrammatic partial cross-sectional view of anotheralternative embodiment of a kit, in which the second transfer portiondoes not include a seal layer and the first and second transfer portionsare separably joined;

FIG. 4 is a diagrammatic partial cross-sectional view of yet a furtheralternative embodiment of a kit, in which the second transfer portiondoes not include a seal layer, the first and second transfer portionsare provided in independent form, and the second transfer portionincludes a second release film peelably releasably bonded to theadhesive layer;

FIG. 5 is a diagrammatic perspective view illustrating an embodiment ofa cavity mold removed from a respective retainer plate;

FIG. 6 is a diagrammatic perspective view similar to that of FIG. 5, butwherein the retainer plate is shown in releasable receipt of the cavitymold;

FIG. 7 is a perspective view depicting an embodiment of a step followingthe step shown in FIG. 6, wherein a volume of prosthetic precursor fluidhas been inserted into the prosthetic cavities of the cavity mold;

FIG. 8 is a perspective view depicting an embodiment of a step followingthe step shown in FIG. 7, wherein a squeegee is shown being draggedacross the outer face of the cavity mold while simultaneously remainingin contact with the guide face of the retainer plate, thereby scrapingprecursor excess from the cavity mold while particularly ensuringremoval of substantially any residual prosthetic material from the guideface;

FIG. 9 is a perspective view depicting an embodiment of a step followingthe step shown in FIG. 8, wherein a release film is applied across theguide face with the first side in contact with the prosthetic precursor,and in the embodiment shown, the first and second transfer portions havebeen provided peelably separably bonded to one another;

FIG. 10 is a diagrammatic cross-sectional view taken along line 10-10 inFIG. 6, wherein the prosthetic cavity is shown empty and ready toreceive prosthetic precursor fluid;

FIG. 11 is a diagrammatic cross-sectional view taken along line 11-11 inFIG. 7, a dashed line being provided to help illustrate the distinctionbetween the prosthetic precursor within the prosthetic cavity and theprecursor excess generally thereabove;

FIG. 12 is a diagrammatic cross-sectional view taken along line 12-12 inFIG. 8, illustrating the precursor excess having been scraped from thecavity mold while removing substantially any residual prostheticmaterial from the guide face;

FIG. 13 is a diagrammatic cross-sectional view taken along line 13-13 inFIG. 9, showing a configuration in which the system shown may be frozenfor a specified period of time in order to allow the prostheticprecursor to harden and become peelably releasably bonded to a transferfilm;

FIG. 14 is a cross-sectional view depicting an embodiment of a step ofejecting a cavity mold from a respective retainer plate, which mayfollow the step illustrated in FIG. 13;

FIG. 15 is a cross-sectional view depicting an embodiment of a step ofextracting the first transfer portion from the cavity mold by bendinglypealing the cavity mold from the first transfer portion;

FIG. 16 is a diagrammatic partially exploded cross-sectional view ofanother alternative embodiment of a kit for transferring a prostheticappliance to the skin of a wearer, in which the kit further comprises apackage portion with front and rear package members and a bubbleelement;

FIG. 17 is a diagrammatic cross-sectional view taken along line 17-17 inFIG. 18, depicting an embodiment of a kit similar to that shown in FIG.16, but in collapsed, fully-assembled form;

FIG. 18 is a diagrammatic perspective view of an embodiment of FIG. 17;

FIG. 19 is a diagrammatic partial cross-sectional view of an embodimentof a kit for transferring a prosthetic appliance to the skin of awearer, illustrating a step of peelingly separating a second transferportion from a respective first transfer portion;

FIG. 20 is a diagrammatic partial cross-sectional view of an embodimentof a step following the step shown in FIG. 19, in which the firsttransfer portion is flipped over with respect to the second transferportion in preparation for a step of applying the adhesive layer to theouter surface of a prosthetic appliance;

FIG. 21 is a diagrammatic partial cross-sectional view of an embodimentof a step following the step shown in FIG. 20, in which the adhesivelayer is shown applied to the outer surface of the prosthetic appliance;

FIG. 22 is a diagrammatic partial cross-sectional view of an embodimentof a step following the step shown in FIG. 21, in which the release filmis shown being peeled from the inner surface of the prostheticappliance;

FIG. 23 is a diagrammatic partial cross-sectional view of an embodimentof a step following the step shown in FIG. 22, in which the innersurface of the prosthetic appliance is ready to be affixed to the skinof a wearer;

FIG. 24 is a diagrammatic partial cross-sectional view of an embodimentof a step following the step shown in FIG. 23, in which the innersurface of the prosthetic appliance has been affixed to the skin of awearer;

FIG. 25 is a diagrammatic partial cross-sectional view of an embodimentof a step following the step shown in FIG. 24, in which water has beenadministered to the transfer substrate, makes contact with the releasecoat, and thereby allows the transfer substrate to be removed;

FIG. 26 is a diagrammatic partial cross-sectional view of an embodimentof a step following the step shown in FIG. 25, in which the transfersubstrate has been removed; and

FIG. 27 is a diagrammatic perspective view of a wearer with prostheticappliances having been applied to his skin in accordance with thepresent invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, like reference numerals designateidentical or corresponding features throughout the several views. Showngenerally at 100 are one or more embodiments of a kit for transferring aprosthetic appliance to the skin of a wearer. Embodiments of such a kit100 typically comprise a first transfer portion 106 and a secondtransfer portion 118. A first transfer portion 106 may include one ormore prosthetic appliances 102 and a release film 108. A prostheticappliance 102 may have an outer surface 110 and an inner surface 112.The release film 108 may have a first side 114 and a second side 116.The first side 114 may be peelably releasably bonded to the innersurface 112. A second transfer portion 118 may include a transfersubstrate 120, an adhesive layer 122 and a release coat 124 disposedtherebetween. The release coat 124 may typically be water soluble. Inparticular embodiments, the transfer substrate and release coat may beprovided in a combined form such as water slide decal paper.

Referring to FIGS. 1 and 2 for illustration, in particular embodimentsof a kit 100, the second transfer portion 118 may include a seal layer126 disposed between the adhesive layer 122 and the release coat 124. Inparticular preferred embodiments, the seal layer may be providedprimarily to seal the tackiness of the side of the adhesive layerdisposed outwardly from the prosthetic appliance 102 once the appliancehas been applied to the wearer. In certain embodiments having a seallayer 126, the seal layer 126 may preferably be substantially waterinsoluble so as not to react with, or at the same time as, a releasecoat 124 which may itself be water soluble. In particular embodiments,the seal layer 126 may be chemically substantially similar to protectivesealers conventionally used in the makeup industry in connection with,for example, prosthetic appliances. Such sealers are frequently used toseal the tackiness of residual pressure-sensitive adhesive which mayremain on a prosthetic appliance after being affixed to a wearer usingprior known transfer methods. More generally, depending upon theparticular embodiment of a kit or method described herein, a seal layer126 may be otherwise referred to as a protective barrier, top coat,varnish, sealer or sealant. It should be understood that, in particularembodiments, the seal layer may be formed of a sealing substance notconventionally used in the makeup arts. Also depending upon theembodiment, a seal layer 126 may be, for example, primarilywater/acrylic based, alcohol/water/acrylic based, alcohol/water based,aqueous based such as sealers for paper products, a conventional makeupsealant or the like.

Referring to FIGS. 3 and 4 for illustration, in particular embodimentsof a kit 100, the second transfer portion 118 may not include a seallayer 126. Once prosthetic appliances 102 from such kits are affixed tothe skin of a wearer, it may be desirable for a conventional makeupsealer to then be applied to the adhesive layer 122 remaining on theouter surface 110 of the prosthetic appliance 102 in order to eliminateor reduce tackiness at the outer surface.

In certain embodiments of a kit 100, such as those shown for example inFIGS. 1 and 3, the first transfer portion 106 and second transferportion 118 may be separably joined by way of the second side 116 beingpeelably releasably bonded to the adhesive layer 122. In certain suchembodiments, the first side 114 and second side 116 may each be treatedwith silicone, a similar release substance or conventional alternative.In typical preferred embodiments of a kit 100, the adhesive layer 122may be substantially or entirely comprised of a pressure sensitiveadhesive, and may be substantially transparent.

Referring to FIGS. 2 and 4 for illustration, in alternate embodiments ofa kit 100, the first transfer portion 106 and second transfer portion118 may be provided in independent form, and the second transfer portion118 may include a second release film 176 peelably releasably bonded tothe adhesive layer. In such embodiments, one or both of the release film108 and the second release film 176 may be, for example,silicone-treated on only one side—that is, the first side 114 of releasefilm 108 and the side of the second release film 176 which is placed incontact with the adhesive layer 122. The release film 108 and secondrelease firm 176 may, for example, be made substantially of an acetate,a bleached paper with silicone or wax-coated barrier, or the like.

Certain embodiments of kits and methods described herein may beappropriately adapted such that the prosthetic appliance 102 may becomprised substantially of a material selected from the group consistingof, for example, water-based acrylic pressure sensitive adhesive,silicone, latex rubber, gelatin, hot melt plastic, hot melt glue,urethane foam and latex foam, similar conventionally-used prostheticmaterials or a combination of one or more thereof. In certainembodiments in which the prosthetic appliance 102 is not comprisedsubstantially of a tacky material such as a pressure sensitive adhesive(for example, if the prosthetic appliance 102 is made of latex) thefirst side 114 may need to be peelably releasably bonded to the innersurface 112 by way of an auxiliary adhesive layer.

In certain embodiments of a kit 100, the prosthetic appliance 102 mayinclude a base color and one or more accent colors. The base color maybe, for example, a conventional neutral prosthetic color or a selectedflesh tone. An accent color, as illustrated for example, in FIG. 18 at128, may be located substantially at the outer surface 110 of theprosthetic 102 and may be visually distinctive from the base color. Suchan accent color may be, for example, a coloration simulating coagulated,oozing or spattered blood, charred flesh, exposed bone, moles, freckles,shading and the like. Accent colors may be applied by way of small paintbrushes or by airbrushing.

Referring to FIGS. 16-18 for illustration, certain embodiments of a kit100 may further comprise a package portion. A package portion mayinclude, for example, a rear package member 132, a front package member134 and a bubble element 136. The bubble element 136 may besubstantially transparent and have a substantially planar flange section138 and a window compartment 140 protruding outward therefrom. The frontpackage member 134 may have a compartment aperture 142 receiving atleast a portion of the window compartment 140 substantially therethough.The front package member 132 and rear package member 132 may beadhesively joined, for example, generally at their peripheries, so as toclampingly and substantially non-adhesively secure the first and secondtransfer portions (106 and 118) between the flange section 138 and therear package member 132. As a result of such securement, the prostheticappliance(s) 102 may be substantially restrained from making contactwith the package portion while remaining viewable from outward of thewindow compartment 140. As shown in FIG. 18, for example, a firsttransfer portion 106 may include a multiplicity of prosthetic appliances102.

Prior to applying a selected prosthetic appliance, a user of a kit 100having multiple appliances 102 may separate the selected appliance 102from the remainder of the first transfer portion 106, for example, bycarefully cutting through the first transfer portion 106 (and secondtransfer portion 118, in applicable embodiments such as those shown inFIGS. 1 and 3), while avoiding cutting through the thin, feathered edgesof the selected appliance 102. It is envisioned that in certainalternative embodiments of a kit 100 with multiple prosthetic appliances102, the first and second transfer portions may feature die cutssurrounding each appliance 102, such that all components of the kitcorresponding to a selected prosthetic appliance 102 may be convenientlyseparated from the others without the need for scissors or similarcutting device.

Embodiments of a method for transferring a prosthetic appliance 102 tothe skin 104 of a wearer 174 may comprise one or more of the followingsteps, which are listed here generally in the order of certain preferredand non-exhaustive embodiments. First, referring for example to FIGS. 1and 19, there may be provided a first transfer portion 106 and a secondtransfer portion 118 in the form of a kit. The first transfer portion106 may include a prosthetic appliance 102 and a release film 108. Theprosthetic appliance 102 may have an outer surface 110 and an innersurface 112. The release film 108 may have a first side 114 and a secondside 116. The first side 114 may be in peelably releasably bondedengagement with the inner surface 112. The second transfer portion 118may include a transfer substrate 120, an adhesive layer 122, and arelease coat 124 disposed therebetween. The release coat 124 may be, forexample, water soluble. Subsequent steps typically include thefollowing: applying the adhesive layer 122 to the outer surface 110(see, for example, FIGS. 20 and 21); peeling the release film 108 fromthe inner surface 112 (see, for example, FIG. 22); affixing the innersurface 112 to the skin 104 of the wearer 174 (see, for example, FIGS.23 and 24); administering water to the transfer substrate 120; andremoving the transfer substrate (see, for example, FIGS. 25 and 26).Ultimately, a primary objective of the transfer method is to provide aconvenient means to affix the prosthetic appliance to the skin of awearer without requiring a person to directly touch the prostheticappliance in the process.

Referring again to FIGS. 20 and 21, in particular embodiments of atransfer method, the step of applying the adhesive layer 122 to theouter surface 110 may result in only a portion of the outer surface 110coming into direct contact with the adhesive layer 122. For example, tothe extent that the prosthetic appliance 102 features deep recesses, theadhesive layer 122 may not make contact with the floor or parts of theinner walls of those recesses.

In particular embodiments of a method for transferring a prostheticappliance 102 to the skin 104 of a wearer 174, the second transferportion 118 may be provided to include a seal layer 126 disposed betweenthe adhesive layer 122 and the release coat 124. Such a seal layer 126may be, for example, substantially water insoluble and substantiallytransparent. In embodiments in which the second transfer portionincludes a seal layer, it may be preferable for the seal layer to besubstantially water insoluble so as not to dissolve when water isadministered to the transfer substrate. As illustrated for example inFIG. 26, embodiments of a method for transferring a prosthetic appliancemay preferably result in the seal layer 126 conveniently pre-sealing thetackiness of the adhesive layer 122. Both the adhesive and sealer layersmay preferably be substantially transparent so that the outer surface110 of the prosthetic appliance 102 may remain visually unobstructed.

In certain embodiments of a method for transferring a prostheticappliance to the skin of a wearer, in the step of providing, the firsttransfer portion 106 and second transfer portion 118 may be in peelinglyseparable bonded engagement with one another, wherein the peelinglyseparable bonded engagement may be, directly or indirectly, between thesecond side 116 and the adhesive layer 122. In such embodiments, forexample, both the first side 114 and second side 116 may each besilicone treated. Referring to FIG. 19 for illustration, particular suchembodiments may further comprise the step of peelingly separating thesecond transfer portion 118 from the first transfer portion 106 prior tothe step of applying the adhesive layer 122 to the outer surface 110 ofthe prosthetic appliance 102.

Embodiments of a method for producing a kit 100 for transferring aprosthetic appliance 102 to the skin 104 of a wearer 174 may compriseone or more of the following steps, which are listed here generally inthe order of certain non-exhaustive preferred embodiments. This ordermay be modified as appropriate. First, there may be provided a releasefilm 108 and a second transfer portion 118. The release film 108 mayhave a first side 114 and a second side 116. The second transfer portion118 may include a transfer substrate 120, an adhesive layer 122 and arelease coat 124 disposed therebetween. The release 124 coat may be, forexample, water soluble. Referring to FIG. 5 for illustration, asubsequent step may involve selecting a retainer plate 144 and a cavitymold 146. The retainer plate 144 may be rigid and may have a guide face148 and a mold pocket 150 extending generally from the guide face 148toward a pocket floor 152.

A cavity mold 146 may be generally flexible and may have an outer face154 and one or more prosthetic cavities 156 extending generally inwardtherefrom. The cavity mold 146 may be made of, for example, a silicone,a flexible urethanes, a mold injected plastic or the like. The materialof the cavity mold 146 must generally be appropriately matched to thematerial used to form the prosthetic appliance 102, particularly insofaras mold release properties and the presence of mold undercuts areconcerned. For example, a particular prosthetic appliance 102 mayrequire a mold having undercuts, the requiring a more flexible andelastic cavity mold material in order to allow for proper extraction ofthe prosthetic without causing it to become damaged during extraction.Referring to FIGS. 6 and 10 for illustration, the retainer plate 144 maybe adapted to releasably receive the cavity mold 146 therein such thatthe outer face 154 is substantially coplanar with the guide face 148.

Referring now to FIG. 7 for illustration, embodiments of a method forproducing a kit 100 may further include the step of inserting a volumeof a prosthetic precursor fluid into the one or more prosthetic cavities156, thereby forming respective prosthetic precursors 158 within eachprosthetic cavity 156, and precursor excess 160 generally thereabove(see, for example, FIG. 11). Referring to FIGS. 8 and 12 forillustration, a further step may involve scraping the precursor excess160 from the cavity mold 146 by dragging a squeegee 162 across the outerface 154 while the squeegee 162 remains in contact with the guide face148.

In particular preferred embodiments, the retainer plate 144 issubstantially rigid, and may be constructed from a rigid urethane, orother rigid material such as stone, plastics, silicones and the like.Due to the rigidity of a preferred retainer plate 144, particularlyrelative to that of a respective preferred cavity mold 146, pressureapplied to the guide face 148 by the squeegee 162 during the squeegeeingstep may be substantially prevented from compressing or deforming theguide face 148. This may provide at least two potential benefits. First,it may protect a softer and more compressible cavity mold 146 from beingdepressed by the squeegee 162 during the scraping operation, therebyhelping to maintain the integrity of the prosthetic precursors 158within the cavity mold 146. Second, it may help ensure thatsubstantially all of the residual prosthetic material is removed fromthe guide face 148 prior to the release film 108 being brought intocontact with the guide face 148. Referring to FIG. 14 for illustration,the later discussed benefit may help provide the first transfer portion106 with a substantially prosthetic-free zone 178, therefore allowing akit 100 to incorporate a package portion while preventing any part ofthat package from sticking to a prosthetic appliance 102 or any otherpart of the first or second transfer portions. FIGS. 16 and 17, forexample, illustrate how a package portion may be adapted to interactwith the other components of a kit 100, wherein the substantiallyprosthetic-free zone 178 allows the flange section 138 of the bubbleelement 136 to make direct contact with the first transfer portion 106while ensuring that such contact remains non-adhesive. Thus, thepackaging can later be opened by an average consumer without suchopening causing damage to the prosthetic appliances inside.

Referring to FIGS. 9 and 13, in embodiments of a method for producing akit 100, following the step of scraping for example, a release film 108may then be applied across the guide face 148 with the first side 114being placed in contact with the prosthetic precursor 158. In certainpreferred embodiments, the release film 108 and the second transferportion 118 are provided in combined form prior to being applied acrossthe guide face. In particular embodiments, once the step of applying therelease film 108 has been performed, the prosthetic precursor 158 may beallowed to cure within the prosthetic cavity 156, thereby transformingthe prosthetic precursor 158 and release film 108 into a first transferportion 106. Referring to FIGS. 1-4 for alternative illustrations, thestep of allowing the prosthetic precursor 158 to cure may therebytransform the prosthetic precursor 158 and release film 108 into a firsttransfer portion 106 including at least a prosthetic appliance 102 and arelease film 108, wherein the prosthetic appliance 102 has an outersurface 110 and an inner surface 112, and the first side 114 is peelablyreleasably bonded to the inner surface 112. Referring to FIG. 14 forillustration, the cavity mold 146 may then be ejected from the retainerplate 144, and, referring to FIG. 15 for example only, the firsttransfer portion 106 extracted from the cavity mold 146.

In particular embodiments of a method for producing a kit 100, thecuring of the prosthetic precursor 158 may be accomplished, at least inpart, by way of cooling or freezing the prosthetic precursor 158. Forexample, the combined retainer plate 144, cavity mold 146, prostheticprecursor 158 and release film 108 (and second transfer portion 118, inrespective embodiments) may be cooled or frozen for a selected coolingperiod.

As previously mentioned, in certain embodiments, the prostheticappliance 102 may not be comprised substantially of a tacky materialsuch as a pressure sensitive adhesive (for example, when the prostheticappliance 102 is made of latex or the like). In such embodiments, thefirst side 114 of the release film 108 may be peelably releasably bondedto the inner surface 112 of the prosthetic appliance 102 by way of, forexample, an auxiliary adhesive layer. One way to achieve this is toapply the auxiliary adhesive layer to the release film 108 or to theinner surface 112 prior to applying the release film 108 to thenon-tacky prosthetic. The auxiliary adhesive layer may be applied bybrushing, spray operation, or other conventional means of applyingadhesive layers. An auxiliary adhesive layer may also result in theestablishment of a tacky surface on the inner surface 112 of anotherwise substantially non-tacky prosthetic appliance, therebyfacilitating the step of affixing of such a prosthetic appliance 102 tothe skin 104 of a wearer 174.

Referring to FIG. 14 for illustration, in certain embodiments of amethod for producing a kit 100, the retainer plate 144 may include atleast one ejector port 164 in fluid communication with the pocket floor152. In particular such embodiments, the step of ejecting the cavitymold 146 may be facilitated by way of the at least one ejector port 164and an ejection force (depicted, for example, at 166) imposed on thecavity mold 146. The ejection force 166 may be, for example, at leastpartially imposed by way of pressurized gas flowing through the at leastone ejector port 164. Alternatively or in addition, the ejection forcemay be imposed by way of ejector pins (not shown) actuated through oneor more ejector ports. In further embodiments, the ejection force may beimposed, in total or in part, by way of gravity, wherein, for example,the retainer plate is at least partially invented (as shown, forexample, in FIG. 14) and one or more ejector ports 164 allow ambient airto flow therethrough to prevent suction from retaining the cavity mold146 within the mold pocket 150.

Referring to FIG. 15 for illustration, in certain embodiments of amethod for producing a kit 100, the step of extracting may includebendingly peeling the cavity mold 146 from the first transfer portion106. Such a peeling operation may be performed, for example, with thefirst transfer portion 106 being supported, directly or indirectly, by asubstantially rigid working surface 172. In certain distinct or furtherrelated embodiments, in the step of providing a release film 108 and asecond transfer portion 118, the second side 116 may be in peelinglyseparable bonded engagement with the adhesive layer 122.

Referring to FIGS. 12 and 14 for illustration, in certain embodiments ofa method for producing a kit 100, the release film 108 may include atleast a pair of laterally opposed film edges 168, the guide face 148 mayinclude at least a pair of laterally opposed guide edges 170, and thestep of applying may be performed to result in each of the film edges168 being substantially adjacently aligned with a respective one of theguide edges 168. As illustrated in FIGS. 9 and 13, in such embodiments,the size and shape of the release film 108 may be adapted to closelymatch the size and shape of the outer periphery of the guide face 148.Referring more specifically to FIG. 9 for illustration, in the same orfurther embodiments, the entire peripheral edge of the guide face 148may be adapted to respectively match the entire peripheral edge of aselected release film 108 and second transfer portion 118, asappropriate.

Particular embodiments of a method for producing a kit 100 may furthercomprise a step of preparing the prosthetic precursor fluid prior to thestep of inserting the fluid into the one or more prosthetic cavities156. This step of preparing may include one or more of the followingsub-steps, which are listed here in one non-exhaustive example of apreferred order: measuring a first weight of a prosthetic base liquid;stirring the first weight for a first period; adding a second weight ofa plasticizer to the first weight; mixing the first weight with thesecond weight for a second period, thereby forming a precursor mix; andpurifying the precursor mix by way of transferring the precursor mixthrough a strainer. In particular embodiments, the prosthetic baseliquid may be a water-based pressure sensitive adhesive. In such anembodiment, the second weight may be, for example, approximately 4.2% ofthe first weight. However, depending upon the firmness required for thefinal appliance, various embodiments may be practiced in which thesecond weight of plasticizer may range from 0.001% to 20% of the firstweight. In certain embodiments, the second period may be at least 20hours. In other embodiments, the second period may be greater than 20hours. In various preferred embodiments, depending upon the desiredresulting viscosity of the precursor fluid, the second period may rangebetween 6 hours and 24 hours. Generally, the longer the second period,the greater the resulting viscosity.

In a particular embodiment of a step of preparing the prostheticprecursor fluid, the first weight may be approximately 600 grams of aconventional prosthetic base liquid (for example, a water-based acrylicpressure sensitive adhesive), and the second weight may be approximately25 grams of a conventional Plasticizer. In such a step, the prostheticbase liquid may be first mixed for a first period of approximately 30minutes, and then the plasticizer added to the base liquid over thecourse of approximately one minute while pouring slowly. The mixer maythen be left to run for a second period of approximately or at least 20hours depending on the desired moisture loss, thus forming anaforementioned precursor mix. The finished product of such an embodimentmay yield, for example, approximately 375 grams of precursor mix, whichmay then be optionally purified by transferring the precursor mixthrough a strainer.

While embodiments of the invention have been illustrated and described,it is not intended that these embodiments illustrate and describe allpossible forms of the invention. Rather, the words used in thespecification are words of description rather than limitation, and it isunderstood that various changes may be made without departing from thespirit and scope of the invention.

1. A kit for transferring a prosthetic appliance to the skin of awearer, said kit comprising: a first transfer portion including aprosthetic appliance and a release film, said prosthetic appliancehaving an outer surface and an inner surface, said release film having afirst side and a second side, said first side being peelably releasablybonded to said inner surface; and a second transfer portion including atransfer substrate, an adhesive layer and a water soluble release coatdisposed therebetween.
 2. A kit as defined in claim 1 in which saidsecond transfer portion includes a seal layer disposed between saidadhesive layer and said release coat.
 3. A kit as defined in claim 2 inwhich said seal layer is substantially water insoluble.
 4. A kit asdefined in claim 1 in which said first transfer portion and said secondtransfer portion are separably joined by way of said second side beingpeelably releasably bonded to said adhesive layer.
 5. A kit as definedin claim 4 in which said first side and said second side are eachsilicone treated.
 6. A kit as defined in claim 1 in which said adhesivelayer is substantially comprised of a pressure sensitive adhesive.
 7. Akit as defined in claim 1 in which said prosthetic appliance iscomprised substantially of a material selected from the group consistingof water-based acrylic pressure sensitive adhesive, silicone, latexrubber, gelatin, hot melt plastic, hot melt glue, urethane foam andlatex foam.
 8. A kit as defined in claim 1 in which said prostheticappliance includes a base color and an accent color, said accent colorbeing substantially at said outer surface and being visually distinctivefrom said base color.
 9. A kit as defined in claim 1 in which said firsttransfer portion includes a multiplicity of said prosthetic appliances.10. A kit as defined in claim 1 further comprising a package portion,said package portion including a rear package member, a front packagemember, and a bubble element, said bubble element being substantiallytransparent and having a substantially planar flange section and awindow compartment protruding outward therefrom, said front packagemember having a compartment aperture receiving at least a portion ofsaid window compartment substantially therethough, said front and rearpackage members being adhesively joined so as to clampingly andsubstantially non-adhesively secure said first and second transferportions between said flange section and said rear package member,wherein said prosthetic appliance is substantially restrained frommaking contact with said package portion and remains viewable fromoutward of said window compartment.
 11. A kit for transferring aprosthetic appliance to the skin of a wearer, said kit comprising: afirst transfer portion including a prosthetic appliance and a releasefilm, said prosthetic appliance having an outer surface and an innersurface, said release film having a first side and a second side, saidfirst side being peelably releasably bonded to said inner surface; and asecond transfer portion including a transfer substrate, an adhesivelayer, a water soluble release coat disposed therebetween and a seallayer disposed between said adhesive layer and said release coat, saidadhesive layer being substantially comprised of a pressure sensitiveadhesive; wherein said first transfer portion and said second transferportion are separably joined by way of said second side being peelablyreleasably bonded to said adhesive layer.
 12. A method for transferringa prosthetic appliance to the skin of a wearer, said method comprisingthe steps of: providing a first transfer portion and a second transferportion, said first transfer portion including a prosthetic applianceand a release film, said prosthetic appliance having an outer surfaceand an inner surface, said release film having a first side and a secondside, said first side being in peelably releasably bonded engagementwith said inner surface, said second transfer portion including atransfer substrate, an adhesive layer and a water soluble release coatdisposed therebetween; applying said adhesive layer to said outersurface; peeling said release film from said inner surface; affixingsaid inner surface to the skin of said wearer; administering water tosaid transfer substrate; and removing said transfer substrate.
 13. Amethod as defined in claim 12 in which said second transfer portionincludes a seal layer disposed between said adhesive layer and saidrelease coat.
 14. A method as defined in claim 13 in which said seallayer is substantially water insoluble.
 15. A method as defined in claim12 in which, in said step of providing, said first transfer portion andsaid second transfer portion are in peelingly separable bondedengagement with one another, wherein said peelingly separable bondedengagement is between said second side and said adhesive layer.
 16. Amethod as defined in claim 15 in which said first side and said secondside are each silicone treated.
 17. A method as defined in claim 15further comprising the step of peelingly separating said second transferportion from said first transfer portion prior to said step of applying.18. A method for producing a kit for transferring a prosthetic applianceto the skin of a wearer, said method comprising the steps of: providinga release film and a second transfer portion, said release film having afirst side and a second side, said second transfer portion including atransfer substrate, an adhesive layer and a water soluble release coatdisposed therebetween; selecting a retainer plate and a cavity mold,said retainer plate being generally rigid and having a guide face and amold pocket extending generally from said guide face toward a pocketfloor, said cavity mold being generally flexible and having an outerface and a prosthetic cavity extending generally inward therefrom, saidretainer plate being adapted to releasably receive said cavity moldtherein such that said outer face is substantially coplanar with saidguide face; inserting a volume of a prosthetic precursor fluid into saidprosthetic cavity, thereby forming a prosthetic precursor within saidprosthetic cavity and precursor excess generally thereabove; scrapingsaid precursor excess from said cavity mold by dragging a squeegeeacross said outer face while said squeegee remains in contact with saidguide face; applying said release film across said guide face with saidfirst side in contact with said prosthetic precursor; allowing saidprosthetic precursor to cure within said prosthetic cavity, therebytransforming said prosthetic precursor and said release film into afirst transfer portion including a prosthetic appliance and said releasefilm, said prosthetic appliance having an outer surface and an innersurface, said first side being peelably releasably bonded to said innersurface; ejecting said cavity mold from said retainer plate; andextracting said first transfer portion from said cavity mold.
 19. Amethod as defined in claim 18 in which said retainer plate includes atleast one ejector port in fluid communication with said pocket floor,and said step of ejecting is facilitated by way of the at least oneejector port and an ejection force imposed on said cavity mold.
 20. Amethod as defined in claim 19 in which said ejection force is at leastpartially imposed by way of pressurized gas flowing through said atleast one ejector port.
 21. A method as defined in claim 18 in whichsaid step of extracting includes bendingly peeling said cavity mold fromsaid first transfer portion.
 22. A method as defied in claim 18 inwhich, in said step of providing, said second side is in peelinglyseparable bonded engagement with said adhesive layer.
 23. A method asdefied in claim 18 in which said release film includes a pair oflaterally opposed film edges, said guide face includes a pair oflaterally opposed guide edges, and said step of applying results in eachof said film edges being substantially adjacently aligned with arespective one of said guide edges.
 24. A method as defied in claim 18further comprising the step of preparing said prosthetic precursor fluidprior to said step of inserting, wherein said step of preparing includesthe sub-steps of: measuring a first weight of a prosthetic base liquid;stirring said first weight for a first period; adding a second weight ofa plasticizer to said first weight; mixing said first weight with saidsecond weight for a second period, thereby forming a precursor mix; andpurifying said precursor mix by way of transferring said precursor mixthrough a strainer.
 25. A method as defied in claim 24 in which saidprosthetic base liquid is a water-based pressure sensitive adhesive,said second weight is between 0.001% and 20% of said first weight.
 26. Amethod as defied in claim 24 in which said second period is at leastapproximately 20 hours.
 27. A method as defied in claim 18 in which saidcure is accomplished, at least in part, by way of freezing saidprosthetic precursor.